Method of producing an assembly puzzle

ABSTRACT

An assembly puzzle toy having separate components shaped to permit edgewise abutment assembly thereof. The components are molded in an exploded arrangement of the figure which is to be assembled with gates holding the components in place. Decorating material is applied to the exploded figure so that when the gates are removed and the components are assembled, the decorating material cooperates to form a recognizable figure. The exploded arrangement of the figure serves as an assembly aid for the person who is to assemble the components.

United States Patent [72] inventor Jerome H. Lemelson 85 Rector St.,Metuchen, NJ. 08840 21 1 Appl. No, 757,662 [22] Filed Sept. 5,1968 [45]Patented Jan. 26, 1971 [54] METHOD OF PRODUCING AN ASSEMBLY PUZZLE 4Claims, 11 Drawing Figs.

[52] U.S.C1 273/157, 46/25; 264/132 51 Int. Cl A63f 9 10 [50] Field ofSearch 273/157; 264/129, 132, 328; 46/17, (cursory), 30 [56] ReferencesCited UNITED STATES PATENTS 1,839,889 1/1932 Palais 46/3OUX 1,525,1032/1925 Orr 273/157 1,974,548 9/1934 Somogyi 264/ 1 32X 2,510,091 6/1950Dofsen et al. 264/328X 2,777,248 1/1957 Hirsch et al 46/ 1 7X PrimaryExaminerAnton O. Oechsle ABSTRACT: An assembly puzzle toy havingseparate components shaped to permit edgewise abutment assembly thereof.The components are molded in an exploded arrangement of the figure whichis to be assembled with gates holding the components in place.Decorating material is applied to the exploded figure so that when thegates are removed and the components are assembled, the decoratingmaterial cooperates to form a recognizable figure. The explodedarrangement of the figure serves as an assembly aid for the person whois to assemble the components.

PATENTEUJANZBIH?! 35551138 INVENTOR. JEROM E H.L EMELSON METHOD OFPRODUCING AN ASSEMBLY PUZZLE RELATED APPLICATIONS The applicant of theinstant invention hereby claims priority as a result ofa provisionalapplication filed in Great Britain on or about Sept. 6, I967.

SUMMARY OF THE INVENTION This invention relates to a constructional toymade of a plurality of molded plastic components which may be assembledin a multitude of different arrays to provide an assembly toy and which,when assembled in a particular manner, will provide a particular,surface-decorated article or toy, thereby permitting the assembly toy toserve also as a puzzle regarding the user with said surface-decoratedarticle or toy when proper assembly is accomplished. Thus, the instantinvention also serves as an educational toy.

It is known in the art to provide picture puzzles commonly known asjigsaw puzzles which consist of a plurality of flat components, usuallydie cut from sheet cardboard and each containing a portion of a totalillustration or picture. Such puzzles or toys generally have thesingular use of providing a picture or illustration when properlyassembled.

It is a primary object of the instant invention to provide an improvedmethod for producing a puzzle or assembly toy.

Another object is to provide a new and improved method for producingarticles of manufacture of molded components which are decorated whileretained in the relative attitudes thereof as molded.

With the above and such other objects in view as may hereinafter morefully appear, the invention consists of the novel constructions,combinations and arrangements of parts as will hereinafter be more fullydescribed, and illustrated in the accompanying drawings, but it is to beunderstood that changes, variations and modifications may be resorted towhich fall within the scope of the invention as claimed.

In the drawings:

FIG. I is a plan view of a constructional toy shown assembled and madein accordance with the teachings of the instant invention;

FIG. 2 is a plan view of a constructional toy in accordance with theinstant invention and made of a plurality of separate assemblablecomponents which are shown retained on gate portions as molded therewithand separately decorated while so retained and prepositioned by saidgate portions;

FIG. 3 is a plan view of one form of assembly toy component or blockhaving end male protrusions;

FIG. 4 is a plan view of a modified form of FIG. 3 having male andfemale connection means at respective ends thereof;

FIG. 5 is a plan view of a modified form of the block of FIG. 3 havingfemale connection means associated with each edge thereof;

FIG. 6 is a plan view of the block of FIG. 5 showing separate connectorsassembled with opposite faces thereof;

FIG. 7 is a plan view of a modified form of block having a plurality ofmale connection means associated with four connecting sides thereof;

FIG. 8 is a plan view of a block having male and female connection meansassociated with respective opposite sides of the block;

FIG. 9 is an isometric view of FIG. 8;

FIG. 10 is a rear view in isometric of the block of FIG. 9; and

FIG. 11 is a plan view of a block which is a modified form of that shownin FIG. 8.

In FIG. 1 is shown a toy assembly 10 made up of a plurality of separateblocklike units 11 which are preferably solid or hollow plastic.Rectangular parallelepiped moldings each representing a separate toycomponent and each having at least two connection formations atrespective opposite ends of the block for assembly with respective otherblock components. The assembly 10 is made up to represent a mock figuresuch as a toy clown and the block units composing said mock figure arechosen from a number of different assembly components such as thoseillustrated in FIGS. 3-11.

Turning first to the components shown in FIGS. 3--ll, in a preferredform of the invention, it is noted that the toy components or blocks 11may each comprise a hollow or solid injection molding or a hollow blowmolding which is substantially rectangular parallelepiped in shape,although by no means is limited to said shape. By providing arectangular parallelepiped block together with a few odd-shaped blocks,it is noted that the assembly toy provided herein be utilized, inaddition to a toy for constructing toy figures and the like, as aconventional block constructional toy of which toy buildings, bridgesand other structures may also be assembled by the child. The toy thusprovided is actually a three-way toy enabling the user to constructconventional structures, mock comic figures and also as a puzzle inwhich a particular figure or scene may be derived upon proper assemblyof the components.

In FIG. 3, a rectangular block unit 11a is oblong in shape, although itmay also be of square shape. Formed at the far ends of the block unitllla are respective protruding formations 12a and 12b which are somewhatcylindrical in shape and are adapted to slide or snap-fit with acylindrical channel such as 13 shown in FIG. 4 and formed in the endwall of another block 11b to be assembled with Ila. The protrusion 12 atthe other end of block 11b is similar in shape to the protrusions 12aand 12b of FIG. 3.

In FIG. 5 the block has cylindrically shaped cavities 13 in each of itsend walls and at least two cavities in each of its sidewalls forassembly purposes.

In FIG. 6 the block 11c of FIG. 5 is shown having fasteners 28 assembledin respective cavities of the sidewalls and shaped to protrude beyondthe outer surfaces of said sidewalls and to slidably assemble withcylindrical cavities shaped in an adjacent block.

In FIG. 7, each of the sidewalls of a block lId have cylindricallyshaped protruding formations formed of the material thereof, there beingtwo such formations l2 protruding from each of the sidewalls and onefrom each of the end walls in the block llld.

In FIG. 8, three protruding formations 12 are formed in a respectivesidewall and end wall and three cylindrical cavities 13 are formed inthe other sidewall and end wall.

FIGS. g and I0 illustrate details of a block 11f having a protrudingformation I2 in one end wall, a cavity 13 in the other end wall, acavity and protruding formation in one sidewall and opposed protrudingformation and cavity in the other sidewall.

In FIG. 10 a block 11 f is shown from the rear side thereof illustratingthat it is hollow. It is noted that two formations of which lIf is onehalf, may be utilized to form a totally enclosed hollow block by bondingor frictional assembly of two of said block formations after they havebeen molded to shape.

In FIG. 11, a square block Hg is molded having respective protrudingformations 12 in adjacent sidewalls and respective cylindrically shapedcavities or channels 13 in the other two adjacent sidewalls. Indicia'26A in the form of a number or letter may be printed on one face of theblock 11g to permit it to be used to form words or sentences.

Returning now to the assembly III of FIG. 1 which utilizes a number ofthe components shown in FIGS. 3-ll, it is noted that the head Ilh of thefigure is made up of two block formations, the upper one of which hasthree cylindrical channels, two in one sidewall and one in the other,while the lower block formation has two channels in one wall and aprotruding formation in the other which snap or slide assemblies withsaid channel in the sidewall of the other block formation. A triangularblock unit M has a pair of cylindrical protrusions extending from onesidewall thereof which frictionally assemble in the cylindrical groovesor channels in the upper sidewall of the upper block formation definingdefining the head of the figure.

The head of the mock figure assembly ll) of HG. is shown having facialfeatures printed on the faces of the two assembled blocks. Eyes arecomposed of a printed portion in on the upper block and a printedportion W on the lower block which printed portions come intoregistration upon assembly of the two blocks and indicate the correctmode of assembling said blocks. Eyebrows 15' are printed only on theupper block while a mouth 18 and nose are printed on and confined to thelower block. The shoulders and upper arm portions of the mock figure arecomposed of blocks 122 of the type shown in FIG. 8, while the forearmportions are composed of respective blocks lib of the type shown in FIG.4. Although not illustrated, the upper arm and forearm blocks maycontain printed illustrations designed to be representative of anextension of the head and neck of the mock figure, as well asillustrations representative of the upper and forearms of the mockfigure. Blocks lllg' which are a modified form of the block shown inFIG. ll an containing four, instead of two, cylindrically shapedchannels in the sidewalls thereof, are shown assembled at the ends ofthe forearm blocks ll 1b to represent the hands of the figure. The torsoportion of the figure is composed of an oblong block 11d which is amodified form of the block shown in FIG. 7 and three additional blocksincluding two lib of the type shown in FIG. 4 and lllb which has but oneprotruding formation 12 at one end thereof. The upper portions of thelegs are each formed by a block 11c as shown in FIG. 5 and are connectedto the ends of the blocks llb of the torso by means of the connectionmeans or pins 28 shown in FIG. 6 which slidably engage in thecylindrical channels of the blocks 11b and lllc. The lower legs are eachformed of blocks Illa of the type shown in FIG. 3 and each connect to ablock llllc' which is modified form of the block lie of FIG. 5 havingcylindrical channels provided in but one sidewall thereof.

It is noted that additional decorative material may extend across aplurality of those blocks comprising the mock figure of FIG. l which arenot illustrated as being decorated if not all of the blocks to define,in much the manner ofajigsaw puzzle, how the component". are intended tobe properly assembled together. For exam the blocks illll), llb' and 11dcompris ing the torso may be decorated with buttons, pockets and otherillustrations representative of the torso of the mock figure. The blocksiic comprising the upper legs may be decorated with indicia such asprinted matter representative of the upper legs or pants of the mockfigure while the blocks Ila may be printed or spray decorated torepresent the lower leg portions of the figure. The blocks lilc' may besurface decorated to represent shoes or feet.

In FIG. 2 is shown an assembly toy 2t? composed of a plurality ofsubstantially rectangular blocks denoted generally by the notation 21and each molded onto a plurality of gates or runners 25 extendingbetween the sidewalls of adjacent blocks which gates are retainedthereon after the blocks are removed from the mold so as to hold saidblocks in predetermined assembly such that they may be easily decoratedonce the assembly is predeterminately located with respect to a printingdevice such as a roll printing means, a reciprocating plate printingmeans, screen printing means, a mask for spray painting one or moreofthe blocks or other suitable means.

Each of the blocks 21 of FIG. 2 is substantially a rectangularparallelepiped having one or more sidewalls thereof provided withdovetailed protrusions 23 and one or more of the opposite or samesidewalls containing undercut channel formations 22 of substantially thesame shape as the dovetail protrusions to permit sliding engagement ofthe protrusions of one block with the walls of the channel of the otherblock and prevent disassembly of the two blocks unless they arelaterally moved to disengage the protruding formation from the channelformed in the mating sidewall. Blocks Zia and 21117 are shown havingrespective illustrations 26a and 2611 which, upon assembly of theblocks, define the head and face of the mock figure or animal denoted26. A respective pair of dovetailshaped protrusions 23 formed in theupper sidewall of the block Zllb are adapted to be frictionally securedin the dovetail shaped channels or cavities in the lower sidewall of theblock 21a. The components 21a and 21b are so gated and decorated thatthe person purchasing or receiving the gated assembly immediately maysee the manner in which the block components are to be assembled.

The torso of the mock animal toy of FIG. 2 is composed of four blocksdenoted 21c, 21d, 21g, and 21h which are held in predetermined assemblywith each other by respective gate portions of the molding. Legs aredefined by block formations Zle, 2llf defining the front legs, whileformations-2li and 21] define the rear leg or legs of the figure. Thefour blocks Zia, 21d, Zllg and 21h which define the torso of the figureare each surface decorated to represent respective portions of the torsoof the figure which, upon assembly of the blocks, properly simulate thedecorated torso. Said decorations are denoted respectively by thenotations 26c, 26d, 26g, and 26h.

The blocks Zle and 21]" representing the front leg or legs of the figureeach contain a respective decoration 26c and 26f which is representativeof the upper portion of the leg or legs of the figure and the lowerportion thereof. The blocks 2li and 2H] representing the rear leg orlegs of the figure are each decorated with illustrations 261 and 26jrepresentative of the upper and lower leg portions of the figure. Aseries of blocks Zllk, 211, and 21m are disposed on respective gateportions of the molding and contain illustrative material printed orotherwise deposited on their outer surfaces which represent, upon properassembly of said blocks, the tail of the mock figure. Notation 22 refersto the dovetail shape channels or cavities molded in the sidewalls ofthe blocks to permit frictional assembly with the dovetail-shapedprotrusions 23 of adjacent blocks.

In a preferred form of the instant invention, blocks of the type shownin FIGS. 2 or 3-H or modified forms of said blocks may be molded inpredetermined assembly or respective gates or runners such as thatdenoted 20 in FIG. 2, retained together on said gates during thedecoration process and furthermore, retained together during packagingof said blocks such as underneath a blister or shrink film wrap toindicate to the purchaser the manner in which the components areassembled and furthermore to indicate, rather approximately, the shapeof the puzzle upon proper assembly. For example, it is quite obviousthat the illustration provided in FIG. 2 is intended to berepresentative of a cat even though the blocks are separated from eachother by respective gate portions 25 as in an exploded drawing. Uponpurchase and use of the puzzle, the blocks may be separated from eachother by cutting or bending so as to remove the gate portions 25 fromthe sidewalls of each block, after which the purchaser may eitherassemble the particular puzzle figure or construct other assemblies ofsaid blocks.

It is to be noted that the block designs illustrated in FIGS. lll may besubject to many different variations in general shape as well asvariations in the illustrated means for assembling said blocks together.In addition to mock figures and animals, various other assemblies may bepresented including certain representing scenes, houses and otherstructures containing surface-decorated illustrations which, upon properassembly of the blocks, provide a picture or object in which theillustrated surface portions match up or are provided in an orderly orpredetermined array.

Various articles of manufacture which require decoration upon assemblyof a plurality of components may be produced by the means shown in FIG.2 of the drawings in which the individual molded components of theassembly are retained gated during the decoration process so that if thegated molding is prepositioned relative to the decoration apparatus,each component will also be so prepositioned and a printing means suchas a roller, silk screen cut, mask or other means when predeterminatelylocated with respect to one or more of the blocks will provideillustrative material which is prepositioned with respect to the otherblocks in the gated assembly in such a manner that, upon proper assemblyof the blocks, all of the illustrated material on the various blockscomes into registration or is otherwise properly located to define anarticle having predetermined shape and decoration upon said assembly.Furthermore, if the gated assembly is retained and prepositioned withrespect to an automatic assembly apparatus, said automatic assemblyapparatus may be operative to automatically degate or remove the runnersfrom the various components and thereafter predeterminately assemble thecomponents to form articles of predetermined shape which arepredeterminately surface-decorated.

lclaim:

l. A method of fabricating a plurality of molded components adapted tobe assembled into an article which article contains predeterminatelylocated surface decorations comprising the steps of:

molding separate components representative of an article made byassembling said components with said components being shaped to permitthe edgewise abutment assembly of the components in a single moldingoperation with said components predeterminately retained together asmolded by a plurality of gates or runners;

retaining said components on said gates as molded and predeterminatelyaligning the gated assembly of components with a surface-decoratingmeans;

while so predeterminately retained together and predeterminately alignedwith said decorating means, selectively applying decorating material bycoating predetermined areas of at least certain of said components todecorate same; and

thereafter separating said gates from said components and edgewiseabutting same to predeterminately assemble said components into anarticle having outwardly facing surface decorations defined by saiddecorating material predeterminately positioned on the surface of saidassembled article.

2. A method in accordance with claim 1, whereby the components arearranged and held together as molded on said gates in an array definingsubstantially an exploded view of the article to be assembled thereof toindicate to the assembler of said components substantially the locationsof the components upon assembly.

3. A method in accordance with claim 1, whereby portions of thedecorating material on adjacent components are designed to extendtogether upon assembly of the components and form a common decoration.said method comprising locating the decorating material on thegate-separated components. so as to effect the alignment of thedecorating material on one component with the decorating materialdisposed on an adjacent component when the two components arepredeterminately edgewise abutted and secured together.

4. A method in accordance with claim 1, including shaping the componentsto define separate portions of a simulated mock figure and molding thecomponents on said plurality of gates in an array representative ofsubstantially an exploded arrangement of the components so as toindicate to the person who is to assemble the components, theapproximate relative positions of the components prior to assembly ofsaid article.

1. A method of fabricating a plurality of molded components adapted tobe assembled into an article which article contains predeterminatelylocated surface decorations comprising the steps of: molding separatecomponents representative of an article made by assembling saidcomponents with said components being shaped to permit the edgewiseabutment assembly of the components in a single molding operation withsaid components predeterminately retained together as molded by aplurality of gates or runners; retaining said components on said gatesas molded and predeterminately aligning the gated assembly of componentswith a surface-decorating means; while so predeterminately retainedtogether and predeterminately aligned with said decorating means,selectively applying decorating material by coating predetermined areasof at least certain of said components to decorate same; and thereafterseparating said gates from said components and edgewise abutting same topredeterminately assemble said components into an article havingoutwardly facing surface decorations defined by said decorating materialpredeterminately positioned on the surface of said assembled article. 2.A method in accordance with claim 1, whereby the components are arrangedand held together as molded on said gates in an array definingsubstantially an exploded view of the article to be assembled thereof toindicate to the assembler of said components substantially the locationsof the components upon assembly.
 3. A method in accordance with claim 1,whereby portions of the decorating material on adjacent components aredesigned to extend together upon assembly of the components and form acommon decoration, said method comprising locating the decoratingmaterial on the gate-separated components, so as to effect the alignmentof the decorating material on one component with the decorating materialdisposed on an adjacent component when the two components arepredeterminately edgewise abutted and secured together.
 4. A method inaccordance with claim 1, including shaping the components to defineseparate portions of a simulated mock figure and molding the componentson said plurality of gates in an array representative of substantiallyan exploded arrangement of the components so as to indicate to theperson who is to assemble the components, the approximate relativepositions of the components prior to assembly of said article.